MXPA97007383A - Fermentation flavors for panade products - Google Patents

Abstract

Flavored baked goods such as breads, buns, pastries, cakes, cereal, biscuits, biscuits, crackers and snack products are prepared using a liquid ferment that typically contains a mixture of lactic acid and acetic acid microbes, such as a mixture of Lactobacillus and Gluconobacter species that grow simultaneously when incubated at 25 to 37 ° C with flour and water to give a ferment having a pH of about 3.6 to 3.9, a determinable acidity of about 0.04 to 0.3 meq / g, an acid concentration lactic acid of approximately 0.5 to 2%, an acetic acid concentration of approximately 0.1 to 1% and a viscosity less than 100 cps. The liquid ferment is maintained in an active state such that a fermented flavor can be continuously generated by adding water and flour and extracting liquid in such a way that the average residence time is approximately 12 to 48 hours. Saccharomyces chevalieri is used as part of the microbial complement in the preferred modalities. When used to make biscuits, concentrations of approximately 3 to 10% of this ferment added to the dough mass that has a fibrous texture and good flavor without the stage of challenge

Description

FERMENTATION FLAVORS FOR BAKERY PRODUCTS DESCRIPTION OF THE INVENTION The invention relates to the addition of certain liquid fermented flavoring / texturing materials to bakery articles to develop improved flavors and textures and to increase stability during storage. Fermenting the dough prior to baking has been known since ancient times to produce breads and other baked goods that have desirable attributes such as improved flavors. The term "fermentation" covers the biochemical changes produced by microorganisms and / or enzymes present in the dough during incubation. The physicochemical properties of the ingredients in the formulations are modified during the process resulting in alterations in volume, texture, taste, smell, color, shelf life and consistency. In modern bakeries the fermentation is typically done in a batch process of dough that requires time and controlled environment chambers, and this increases production sums. This is particularly true for bakery products of acid mass and those that have some properties of the acid doughs because these generally require additional residence time in a fermenter for proper flavor development. In some cases, the fermentation is __ performed at different temperatures to give certain notes of < ^ "Taste: Historically, the acid masses were made by adding a mother acid inoculum to a flour / water mixture, and the resulting mass was mixed and left to ferment for several days.The product was removed and a portion was saved as a new mother-acid inoculum for the next load With multiple stages of fermentation, the overall process can be very inefficient for commercial scale operations.A number of methods have been considered for mass production of yeast dough and acid dough , and various processing techniques with the type of bakery product produced In US Patent No. 2,953,460 Baker describes a process that includes obtaining a fermented sponge pre-set that was added to a pre-mixer together with flour and other ingredients at the end of a continuous dough making process. The operation and delicate operation of making the sponge could be avoided by using a fermented yeast liquor (column 16, lines 19 to 35). This is I made by mixing yeast with water containing sugar and other nutrients for yeast and fermenting for several hours. The different ingredients, that is the dry ingredients, the fat and the additives, were mixed with the infusion in a pre-mixer. 25 Doerrry et al., Described other uses of yeast liquid ferments in many bakeries in continuous baking processes (American Institute of Baking Technical Bulletin VII, edition 6, June 1895, pages 1-9). The parameters involved in the processes differ widely from bakery to bakery, but typically include the fermentation of approximately 30 to 50% of the flour in a recipe with some sugar, buffering agents, yeast and water. A lower temperature for example 25.55 ° C and not 30 ° C and a long fermentation time It could produce a liquid liquid useful for making high quality bread products. For the acid masses, a special dough fermentation is used. This traditionally includes special fermentation processes and selection of mother acids or mixed microbial mixtures as starting agents for the masses. The fermentation which includes a waiting period for a number of hours in a cold environment is especially preferred for the full development of the flavor of some products. These processes are often described as "delayed", as growth conditions retard the development of common yeasts and promise the growth of the lactic acid and acetic acid producing bacteria that provide the essential metabolic substrates of microorganisms for flavors and odors Characteristics of the acid masses and the products having acid mass characteristics.

Commercial preparations of acid mass include bulk dough fermentations that can be batch-wise or continuously (See Meuser, F., Cereal Foods World 40: 114-122, March 1995). Since batch preparation does not only require many tanks, but also slow and difficult to automate, continuous fermentation is preferred, or combinations of batch or continuous methods. The different systems typically include a two-step fermentation in at least one fermenter. The freeze-dried natural acid-base initiators such as those described in U.S. Pat. do not. 4,140,800 of Kline can be used but these are typically used in place of a mother acid inoculum. The manufacture of current bakery products is similar, and suffers from the same disadvantages in terms of tank volume and complex fermentation steps with conventional sponge acid formulations. Attempts have been made to return to the more flexible dough preparations with regard to the time and temperature cycles required for fermentation. As summarized by Meuser, mentioned above, in some cases mature suspensions of yeast (liquid ferments) are used but when closed fermentation tanks are used, the systems are inefficient because the yeast proliferation is low under anaerobic conditions. In addition, the tanks must be large enough to allow foaming and prevent spills. Meloan and Doerry describe the typical production of a white bread or bun without the fermentation stage before preparation because fermented doughs tend to produce breads with a non-uniform grain structure that can be difficult to form into rings ( American Institute of Baking Technical Bulletin X, edition 4, April 1988, page 8). Raw breads are placed in trays and tested, or more commonly placed for 12 to 18 hours in a retarder at 1.7 to 5.5 ° C (or sometimes frozen). Refrigeration tends to give a better flavor and aroma to the breads subject to the conventional continuous process. It would be desirable to have improved processes for the economic production of bakery items, particularly those with fermentation notes as expected from good breads. It would also be desirable to have a rapid and economical process for producing bakery products without the elaborate fermentation steps and the foam formation problems typically observed. It is an object of the invention to provide fermented / textured flavor materials for rolls and other bakery items. It is another more specific object of the invention to provide liquid ferments by means of a continuous process.

These and other objects are achieved by means of the present invention, which provides a fermented flavor concentrate for yeast-swollen products, particularly white bread. In preferred embodiment, the fermented concentrates of the invention continuously produce a balanced arrangement of microorganisms that provide the required acids and aromatic compounds necessary to impart desirable characteristics to the dough to which the ferment is added. When the concentrates of the invention are added to the dough, a step delayed in the manufacture of the product can be eliminated without compromising the texture of the product, its smell or its taste. In the typical practice of the invention, tasty baked goods are prepared by: a) preparing a liquid ferment in a fermentation tank, the liquid ferment containing flour, water and microbially stable mixed cultures, the ratio of flour to water in the ferment being of about 1: 0.5-2.0 and the ferment contains at least one acid-generating microbe; b) maintaining the liquid ferment in an active state in such a way that a fermented flavor is generated and the average residence time for the ferment of the tank is at least 12 hours; c) continuously adding water and flour to the fermentation tank in an amount that is essentially equal to the amount of fermented liquid that is extracted from the tank; e) adding the liquid ferment to a dough formulation, such that the liquid ferment constitutes from about 1 to 15% by weight * of the formulation; and f) baking the dough. In preferred embodiments, the liquid ferment contains a mixture of microbes that produce lactic acid and / or acid acetic, preferably both, such as a mixture of Lactobacillus and Gluconobacter species that grow together when incubated at about 25 to 37 ° C with flour and water for at least about 24 hours to give a ferment that - ^ have a pH of about 3.6 to 3.9, an acidity of ^ 10 about 0.04 to 0.3 meq / g (more closely from about 0.10 to 0.26 meq / g), a lactic acid concentration of about 0.5 to 2%, an acetic acid concentration of from about 0.1 to 1%, and a viscosity from less to approximately 100 cps. A yeast of Sacchromicyces, such as Saccharomyces chevalieri, should be included as part of the microbial complement to generate aromatic compounds. An illustrative modality, when used to make bread, yields about 3 to 10% of this ferment added to the dough results in breads having a texture chewable and good taste without a delay stage. BRIEF DESCRIPTION OF THE FIGURES Figure 1 is a graph showing the growth and leveling of acidity over time. Figure 2 is a line graph illustrating the acidity 25 determinable with time (for two different proportions of flour + water to starter) in the preparation of a ferment of the invention. Figure 3 is a diagram of a continuous process for producing a fermented flavor for baked goods using a process of the invention. Detailed Description of the Invention The invention is based on the formulation of a fluid concentrate with the desired attributes can be used as a dough additive to save the fermentation stages in the manufacture of buns or similar bakery products. When used in the production of tasty baked goods, the concentrated ferment can eliminate a retardation step during production, and provide bakery products having the characteristics of those prepared with a retardation step. By preparing the liquid ferment in the continuous manner described in this case, foam formation is eliminated. Fermentation of a mixture of one part flour, one part water and microorganisms in a batch system will result in the formation of relatively viscous fluid foam. In contrast, the liquid medium that is present during the continuous fermentation process of the invention does not retain the carbon dioxide formed and thus little or no foam is produced. In practicing the invention, tasty baked goods are prepared by: a) preparing a liquid ferment in a fermentation tank, the liquid ferment containing flour, water and microbially stable mixed cultures, the ratio of flour to water in the ferment of approximately 1: 0.5-2.0 and the ferment contains at least one acid-generating microbe; b) maintaining the liquid ferment in an active state such that a fermented flavor is generated and the average residence time for the VXKC ferment in the tank is at least 12 hours; c) continuously adding water and flour to the fermentation tank in an amount that is essentially equal to the amount of fermented liquid that is extracted from the tank; e) adding the liquid ferment to a dough formulation, such that the liquid ferment constitutes from about 1 to 15% by weight of the formulation; and f) baking the dough. Any microorganism commonly used for the production of bread can be used as a primary organism for initial liquid ferment. Preferred ferments contain a lactic acid generating microbe and an aromatic generating microbe. Examples include, but are not limited to, Lactobacillus species, Gluconobacter species, and Saccharomyces species. The microbes should be those that grow together at the same time in the fermentation tank to provide a balanced array of microbial by-products that have unexpectedly good properties. A yeast that generates an aromatic compound, such as Saccharomyces chevalieri, is particularly preferred in these embodiments. As summarized above, the ferment is prepared by initially mixing flour and water in a ratio of approximately 1: 1 and add microorganisms. At this time, the original mixture is typically viscous, for example up to 40,000 cps. After fermentation the viscosity drops to less than about 2000 cps, preferably less than 100 cps, in some cases less than about 50 cps so that the ferment is a fluid, pumpable and fluid. As microorganisms grow, they produce carbon dioxide. Since the __ Ferrous viscosity is low, carbon dioxide is not G1 10 retains in the ferment, but easily escapes with little or no foam. The liquid ferment is kept in a tank for a period of time under conditions to generate a fermented flavor. This is typically achieved by maintaining the ferment at about 25 to 37 ° C, more closely for 30 minutes at about 35 ° C. during at least approximately 48 hours, for the total flavor development. As shown in the following examples, aromatic compounds and such as ethyl acetate, isoamyl alcohol, isoamyl acetate are formed during fermentation. Acids are also formed. In preferred embodiments the liquid ferment is self-maintained at a pH of from about 3.2 to about 3.9, more closely from about 23.6 to 3.9. The determinable acidity typically varies between 0.04 to 0.3 meq / g. In some embodiments, the acidity varies between approximately 0.15 to 0.26 meq / g; in other modalities, it is ^^ smaller, for example from 0.1 to 0.15 meq / g. In illustrative embodiments, the liquid ferment contains from about 0.5 to 2% lactic acid and from about 0.1 to 1% 5-acetic acid. One embodiment contains about 1.3 to 1.4% lactic acid and about one tenth of that amount of acetic acid. Once the ferment has been prepared and is ready _ to be extracted is extracted continuously or essentially ? T 10 continuous, this is with short periods of interruptions such as intervals of 0 to 15 minutes, with intervals of 5 minutes or less being preferred. Flour and water are added correspondingly to the tank. The ferment can be used in one place or sent frozen or refrigerated to another bakery to add the masses. The addition of water and flour to the ferment can also be carried out essentially continuously. The liquid ferment of the invention can be added to the dough of any bakery product, including without being limited to breads, buns, pastries, cakes, cereal, biscuits, biscuits, crackers and snack products, and mixtures or premixes of ingredients of any of those. It is particularly useful to provide the desirable seasoning and texture to yeast-foamed products consisting of yeast, flour, water and / or milk and other types of such products. In the production of buns that are fibrous and have a trace of acidity, the liquid ferment is added to the dough at a level of from about 2 to about 10% by weight. As is illustrated in the following examples, in some embodiments, additional yeast is added, this is about 1.5 to 2.5 times the usual amount, it is added to the dough to compensate for the delay stage. The mass of the white bun is divided gives it __ Bun form, let stand for half an hour m 1 10 approximately, for example at 30 ° C / 85% relative humidity, cook in a bain-marie and / or steam and bake. An advantage of the invention is that the process can be used to prepare manufactured bakery products such as buns that have the flavor, aroma and texture of a bread bun. bakery without a delay stage, which is typically at least 5 or 6 hours at approximately 4.4 ° C. Thus the process of the invention provides a distinct advantage over the conventional manufacture of buns. The containers, delaying stages and excessive foam are eliminated. It is another advantage of the invention that in embodiments containing a mixture of Saccharomyces, Lactobacillus and Gluconobacter, the three varieties of microorganisms grow simultaneously to produce the aromatic compounds and acidity required for the character of the baked goods made from masses that are fermented generally for long periods _ to achieve the spicy notes required. It is another advantage of the invention that the process can be adapted for continuous, semi-continuous, or batch mass processes. It is particularly suitable for continuous operations. The following examples are presented to illustrate and explain the present invention and should not be considered as limiting in any way. Unless otherwise indicated, all __ Parts and percentages are by weight and are based on the stage of ^ Sr '10 processing that is being described. EXAMPLE 1 To simulate a continuous process of the invention in a table operation, a liquid ferment composed of 1 part of mother ferment, 8 parts of flour and 10 parts of water, this was mixed and left to ferment for a total of 8 days. At the beginning of each day, half of the ferment was removed for a total of 8 days. At the beginning of each day, half of the ferment was removed for analysis and an equal weight of 8:10 flour / water. Thus the total weight of the ferment remained constant. The fermentation was carried out at approximately 22 ° C to approximately 22 ° C. The fermentation was analyzed with respect to its acid composition. The acid production was related to the degree of fermentation. The results of the analysis are given below: Age 25% acid% acid p_H TA (meq / cr1 (days) acetic lactic acid 1 1.37 0.11 3.89 0.121 2 0.94 < 0.05 3.86 0.109 5 3 1.04 0.11 3.88 0.124 4 1.01 0.12 3.85 0.128 5 1.02 0.14 3.87 0.127 6 0.87 0.14 3.92 0.110 7 0.97 0.16 3.89 0.125 10 8 1.07 0.19 3.85 0.144 In addition, the product is thinned to a significant degree over a period of 24 hours. EXAMPLE 2 A batch fermentation was carried out in a reactor of 75 gallons to determine the residence time -necessary to develop the desirable acidity in the ferment. This experiment was the third in a series of batch fermentations. The mother or initial ferment was the product of the one generated in example 1. A 227 kg ferment was made by combining 93 kg of flour, 113.5 kg of water and 20.7 kg of initiator. During a 48-hour period the acidity increased as follows: Time (hours) pH TA (meq / g ') * 0 4.7 0.037 18 3.78 0.143 24 3.79 0.163 5 48 3.76 0.182 These results are shown in figure 1. After eighteen hours the acidity had essentially leveled off. An average residence time of at least 12 hours therefore is considered necessary for this invention. As can be seen from the data and Figure 1, a residence time of 12 hours is required to generate a TA of approximately 0.12 meq / g corresponding to approximately 1% lactic acid, 0.1% acetic acid and a pH of 3.9. EXAMPLE 3 This example illustrates another analysis of the liquid ferment of the invention; however with different levels of initial ferment. Two ferments having a flour: water: initiator ratio of 9: 9: 1 and 5: 5: 1 were prepared and each ferment was maintained for 116.5 hours in a batch process at room temperature (approximately 23 ° C). The demonstrable acidity rose steadily, and in a similar manner in both samples for approximately 16 hours and then leveled out after approximately 24 hours. A titratable acidity profile is illustrated in Figure 2. These results demonstrate that the initial level of starter ferment in the batch can vary and produce acceptable product. 9: 9: 1 5: 5: 1 Age (h) m TA pH TA initiator 3.78 0.1645 3.78 0.1645 0 5.05 0.034 4.79 0.0395 2 4.87 0.0385 4.43 0.0545 18 3.93 0.1415 3.98 0.1445 27 3.88 0.1595 3.93 0.1585 3 3..1155 3 3..8888 0.169 3.93 0.165 42.5 3.86 0.1925 3.90 OJ-755 48.5 3.83 0.1895 3.89 0.1715 52.5 3.84 0.1905 3.89 0.186 66 3.85 0.1915 3.88 0.1823 7 700 - '- 3 3..8866 0.192 3.87 0.185 116.5 3.83 0.2075 3.85 0.1905 EXAMPLE 4 The production of a continuously produced fermented flavor pilot plant of the present invention is described in this example. To start the process, a batch of 227 kg of fermented flavor is started by mixing 92.9 of flour, 113.5 kg of water and 20.7 kg of starter ferment. The liquid ferment propagates during two days for the optimal development of flavor and texture. At this time, the continuous process begins. Flour is added to the batch in the reactor at a rate of about 0.037 kg per minute using a positive displacement or screw feeder that is fed by a vibratory feeder. The water is fed to the reactor the same speed using a metering pump. The liquid ferment is extracted from the bottom of the reactor at a rate of 0.07 kilograms per minute using a positive displacement pump. A timer placed on the scraper initiator motor and the agitator in the reactor to shut off periodically [approximately five minutes every two hours]. The process is illustrated in Figure 3. Physical parameters observed over time in the continuous production of a liquid ferment of the invention were recorded. Samples were taken with intervals indicated in the following table. Yeast count, pH, determinable acidity,% lactic acid and levels of ethyl acetate, isoamyl alcohol and isoamyl acetate were measured. The following results were obtained: Aroamatic levels P < 3 / < 2 Age ChJ ph TA Alcohol acetate% acetate count [meq / gn] lactic yeast isoamyl isoamyl isoamyl (xlo_d 0 3.91 0.141 13 - 609 38.7 2.0 2 3.83 O.135 - 1.05 - - - 7 3.71 0-147 IO JL.O 0 33.7 2.2 31 3.67 O.157 - 1.15 - - - 36 3.67 0.158 9.1 1.34 540 38.5 7.4 40 3.67 O.152 - 1.33 - - - 51 3.74 0.123 9.6 1.19 470 8.4 2.5 Viscosity at zero moment = 40,000 cps Viscosity after 51 hours = 40 cps EXAMPLE 5 In this example, the buns made using a dough for buns from the invention and without delay are compared with those made using a conventional formula processed with a 6 hour delay stage. Approximately 260 buns are prepared in each run. The yeast is hydrated in a portion of water at 12.8 to 17.5 ° C. The ingredients are mixed at low speed for 30 seconds and then the yeast slurry is added. The dough is mixed for another 1.5 minutes at low speed, and then 10 minutes at a higher speed until the dough is at 30 ° C and has developed. The buns are then formed and allowed to stand at 32 ° C / 85% R.H. The control buns are then delayed at 5 ° C for 6 hours before baking, drying and baking (9.5 minutes). The experimental buns are baked, dried and baked under identical conditions without the six hour delay stage. The control and experimental masses were formulated as follows: Control Gram ingredients Flour 100.0 15890 Water 56.0 8898 Corn syrup HF 3.75 595 Yeast 1.00 159 Salt 2.00 318 Experimental Gram ingredients Flour 100.0 15890 Water 56.0 8898 Corn syrup HF 3.75 595 Yeast 2.00 318 Salt 2.00 318 Ferment (produced 6.0 1561 in example 4) In taste tests performed by a panel of at least 10 experts and manufacturers of buns, __the prepared experimental buns using the ferment of the invention they had an aromatic composition, acidity, texture, and characteristics of the crumbs comparable to the control buns. The foregoing description is intended to illustrate and not to limit the present invention, and that of teaching a person with ordinary experience in the art of how to put the invention into practice. It is not intended to detail all those obvious modifications and variations thereof that would become apparent to a skilled worker upon reading the present description. However, it is intended that all those M ^^ 10 obvious modi fi cations and variations are included within the scope of the present invention as defined in the appended claims. The claims are intended to cover the components and stages claimed in any sequence that is effective to achieve the intended objectives, unless the context specifically indicates otherwise.

Claims (20)

CLAIMS 1. - A process for the production of flavored baked goods comprising the steps of a) preparing a liquid ferment in a fermentation tank, the liquid ferment containing flour, water and microbially stable mixed cultures, the proportion of flour being to water in the ferment of approximately 1: 0.5-2.0 and the ferment contains at least one acid-generating microbe; b) maintaining the liquid ferment in an active state of ^ F "10 such that a fermented taste is generated and the average residence time for the tank VXKC ferment is at least 12 hours, c) continuously or essentially continuously adding water and flour to the fermentation tank in an amount that is essentially equal to the amount of fermented liquid that is extracted from the tank, e) adding the liquid ferment to a dough formulation, such that the liquid ferment constitutes approximately

1 to 15% by weight of the formulation; and 20 f) bake the dough.

2. A process according to claim 1 wherein the liquid ferment contains a lactic acid generating microbe and an acetic acid generating microbe. 3. A process according to claim 2 wherein the liquid ferment is self-maintained at a pH of about 3.2 to

3.9.

4. - A process according to claim 3 wherein the liquid ferment contains from about 0.5 to 2% lactic acid and from about 0.1 to 1% acetic acid.

5. A process according to claim 1 in which the liquid ferment is added to a dough for bread, bun, cake or cereal.

6. A process according to claim 5 in which the liquid ferment is added to the dough at a level of about 10 to 10% by weight.

7. A process according to claim 5 in which the ferment-liquid contains a lactic acid generating microbe a microbe generating acetic acid and a yeast generating aromatics.

8. A process according to claim 7 in which the liquid ferment self-maintains at a pH of about 3.2 to 3.9.

9. - A process according to claim 8 in which the liquid ferment contains 0.5 to 2% lactic acid 20 and from 0.1 to 1% acetic acid.

10. A process according to the claim. 9 characterized in that the liquid ferment has an average fermentation time of at least about 24 hours. "

11. A process according to claim 10 in the 25 which the liquid ferment has a demonstrable acidity of approximately 0.04 to 0.3 meq / g.

12. A process according to claim 11 wherein 1 demonstrable acidity is from about 0.10 to 0.26 meq / g.

13. A process according to claim 11 in which the liquid ferment added to the dough has a viscosity less than about 100 cps.

14. A process according to claim 11 in which the yeast is Saccharomyces chevalieri.

15. A process for the production of flavored baked goods comprising the steps of: a) preparing a ferment-liquid in a fermentation tank, the liquid ferment containing flour, water and microbially stable mixed cultures, the proportion of flour being to water in the ferment of approximately 1: 0.5-2.0 and the ferment contains at least one acid-generating microbe; b) maintaining the liquid ferment in an active state such that a fermented flavor is generated and the average residence time for the VXKC ferment in the tank is at least 12 hours; c) continuously or essentially continuously adding water and flour to the fermentation tank in an amount that is essentially equal to the amount of fermented liquid that is extracted from the tank; e) adding the liquid ferment to a dough formulation, such that the liquid ferment constitutes approximately from 1 to 15% by weight of the formulation.; and f) baking the dough.

16. A process according to claim 15 wherein the microbial cultures comprising a mixture of Saccharomyces, Lactobacillus, are Gluconobacter species.

17. A process according to claim 16 in which the liquid ferment has a demonstrable acidity of from 0.04 to 0.3 meq / g, and has a viscosity less than * 10 about 100 cps.

18. A process according to claim 17 wherein the ferment contains from about 0.5 to 2% lactic acid and from about 0.1 to 1% acetic acid.

19. A process according to claim 18 in which "the dough in a bun dough, and where the bun dough is divided, receives the form of bun, is tested, cooked and baked without a stage

20. A process according to claim 19 in which the liquid ferment is added to the mass of the bun at a level of about 3 to 10% by weight.